Interlocking blocks and a method to build walls

ABSTRACT

A massive block preferably made of compressed earth is described as well as a method to build walls utilizing the massive blocks. By combining wooden frame construction and massive wall construction with bricks or other massive block elements, a wall can be built with the advantages of both. A wooden stud frame is erected, the electricity and other utilities are placed through the frame and then the frame is covered up on both sides with large massive blocks of a specific design that interlock with both the frame and each other. The cavities in between the blocks can then be filled up with a filler such as sand to create additional thermal mass and improve the sound insulation properties of the wall. A second embodiment of the wall utilizes an extra layer of blocks with grooves to accommodate a radiant heating system and insulation material.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to provisional patent application 62/488,973 which was filed on Apr. 24, 2017, and is hereby expressly incorporated by reference in its entirety.

BACKGROUND OF THE INVENTION

The present invention relates to a method to build massive walls using a combination of a frame and massive blocks that interlock both with each other and partly interlock with the frame. The frame is preferably wooden, however, a variety of building materials can be utilized. The blocks are preferably compressed earth blocks; again, the blocks can be made of a wide range of building materials including cement and adobe. The arrangement of the blocks relative to the frame creates a cavity that can be filled up with either loose sand or insulation material.

Currently, the majority of builders typically utilize either lightweight wooden frame walls covered with gypsum board/drywall or massive walls from either stone, cement, fired clay bricks, adobe or compressed earth blocks. Wooden frame walls have the advantage that they are quick and cheap to build, and allow for better insulation, as the open spaces can be filled with insulation materials. Use of wooden frames also allow for prefab construction. Massive walls have the advantage that they stop the sound transfer between rooms much better than drywall and also create thermal inertia. The massive walls have the disadvantage of generally take much longer and are more expensive to build.

It is therefore an object of the invention to provide massive blocks that can be made into a wall.

It is a further object of the invention to provide a massive wall system that can be built quickly and at a reduced cost.

SUMMARY OF THE INVENTION

This invention is a method to combine the advantages of both wooden frame construction and massive wall construction. An internal wooden frame is first built and allows the builder to run utility lines and accessories such as electricity, plumbing, and ethernet through the frame. The internal frame is then covered on both sides with large massive blocks that interlock with both the frame and each other. At least one cavity is formed between the sides created by the massive blocks. The cavities in between the blocks can be filled up with a filler such as sand to create additional thermal mass and superior sound insulation (mostly suitable for interior walls); while a second embodiment utilizes an extra layer of blocks and a radiant heating tubes plus insulation (mostly suitable for exterior walls).

BRIEF DESCRIPTION OF THE DRAWING

FIG. 1 is a top view of a massive block;

FIG. 2 is a right side view of the massive block;

FIG. 3 is a left side view of the massive block;

FIG. 4 is a front view of the massive block;

FIG. 5 is a perspective view of the massive block;

FIG. 6 is a perspective view of a wall system made of a frame and massive blocks;

FIG. 7 is a more detailed perspective view of the wall system;

FIG. 8 is a perspective view of a second embodiment of the wall system;

FIG. 9 is a top view of the second embodiment of the wall system;

FIG. 10 is a perspective view of the second embodiment of the wall system showing radiant heating.

DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION

Referring to FIGS. 1-5, show a first invention of a massive block 20. In regard to this application, the term massive block can be used interchangeably with the term massive brick. In regard to this disclosure, the term massive block or massive brick means blocks made of concrete, adobe, or compressed earth, or rock. Each block 20 has a top 24, a bottom 26, a first side 28, a second side 30, a front side 32, and a back side 34. The blocks 20 are made to be stackable and connect with one another utilizing a tongue and groove system.

While the tongue and groove can be on a variety of parts of the block, the preferred embodiment has a first tongue 36 on the top 24 and a second tongue 38 on the first side 28 of the block. Additionally, a first groove 40 is on the bottom 26 and a second groove 42 is on the second side 30. The front side 32 is preferably flat, while the back side 34 has a plurality of features to assist in making contact with a frame 50.

The back side 34, as best shown in FIGS. 1 and 5, has a first channel 44. The first channel 44 spans the entire length of the back side 34 from the top 24 to the bottom 26 of the block 20. The first channel 44 is a vertical channel that is sized to accommodate a first portion 52 of the frame 50.

In the preferred embodiment, a second channel 46 and a third channel 48 are also used to assist in attaching the block to a second portion 54 and a third portion 56 of the frame 50. Again, as best shown in FIGS. 1 and 5, the second channel 46 is located where the back side 34 and the first side 28 meet. Accordingly, the second channel 46 is a notch on the back edge. The second channel 46 spans the entire length of the back side 34 from the top 24 to the bottom 26 of the block 20. The second channel 46 is a vertical channel that is sized to accommodate the second portion 54 of the frame 50. The third channel 48 is located where the back side 34 and the second side 30 meet. Accordingly, the third channel 48 is a notch on the back edge. The third channel 48 spans the entire length of the back side 34 from the top 24 to the bottom 26 of the block 20. The third channel 48 is a vertical channel that is sized to accommodate the third portion 56 of the frame 50. A fastener 70 can be part of the block 20, in which fastener 70 is physically connected to the frame 50. Preferably the fastener 70 is shaped such that it at least partially wraps around the first portion 52 of the frame 50.

FIGS. 6-7 show a wall system 120 made from the blocks 20, the frame 50, and a filler 80. The frame 50 has a plurality of vertical members 124 connected by a first horizontal member 126 and a second horizontal member 128. Then blocks 20 are added to a first side 130 of the frame 50 to make a horizontal row 134 of blocks 20. The first side 28 of a block 20 is joined with the second side 30 of a second block 20 by using the tongue and groove. The blocks 20 are placed such that the first channel 44 makes contact with a first vertical member 124; the second channel 46 makes contact with a second vertical member 124; and the third channel 48 makes contact with a third vertical member 124. The rows 134 are offset such that the first channel 44 of one row 134 is in line with either the first side 28 or second side 30 of a row 134 above or below the particular block 20. The top 24 of a first block 20 in a first row 134 makes contact with the bottom 26 of a second block 20 in a second row 134 above the first row. The fastener 70 of each block 20 is then attached to the frame 50 with a known fastening mechanism such as screws, nails, staples, etc.

Again referring to FIGS. 6 and 7, the exact method utilized for the first side 130 of the frame 50 is utilized for the second side 132 of the frame 50. After this step, a cavity 150 is formed between a first side 160 of the wall system 120 and a second side 162 of the wall system 120. Electrical wiring and other utilities (water, Ethernet cables, etc.) can be placed and run in the cavity 150, preferably prior to placing the blocks 20, thus saving time and money.

As constructed, the wall system 120 has the blocks 20 partly inside the frame 50 due to the use of the first channel 44, second channel 46 and third channel 48. This feature allows the blocks 20 to prevent the vertical members 124 from bending sideways under the weight of the overall structure, which increases the load bearing strength of the frame 50. Similarly, the use of the tongue and grooves both reinforces the strength of the blocks 20 and allows the blocks 20 to cover the frame 50 with a smooth finished surface. After the blocks 20 are placed the cavity 150 can then be filled up with the filler 80 which is preferably loose sand. Loose sand is known for its superior qualities in terms of blocking sound transfer. The sheer mass of the blocks 20 along with the connecting features of the blocks 20 and fastener 70 allow the filler 80 to be placed without pushing the blocks 20 out of position. While sand is preferably used for interior walls of the structure, exterior walls can utilize a filler 80 made of insulation material. Other options include wider walls where both insulation materials and additional mass is placed (either by having sand or additional layer of blocks).

While a variety of shapes and sizes of a block 20 can be utilized, a typical size for a block could be two feet wide by two feet high by three inches thick. The blocks can be made either through casting in a mold (in the case of cement or adobe) and letting them dry, or by compressing a combination of raw materials (sand and clay, sand and limestone, sand, clay and cement, etc.) through a shape that will result in the block having the shape as describe. Another possible method for forming the blocks 20 is by cutting them from larger massive blocks.

There are also different ways to attach the blocks 20 to the frame 50. Other possible variations are that the blocks 20 can be screwed on the frame 50 from the front of the blocks 20 through holes (not shown) in the blocks, or attached using an angular iron that is either screwed on from the back or a piece of metal strip that is integrated in the blocks 20 during the casting method and then screwed on the frame 50.

FIGS. 8-10 show a second embodiment of a wall system 200. The wall system 200 is similar to the wall system shown in FIGS. 6-7, but adds additional features to make the wall system 200 better suited for an exterior wall. As best seen in FIG. 9, the wall system has a first side 210 and a second side 220. The wall system 200 has a frame 230 that has a plurality of vertical members 231, of which some of the members 231 are connected via linkages 232. Again referring to FIG. 9, the wall system 200 comprises blocks 20 in three separate columns. A first column 238 is located on the second side 220, a second column 239 is located between the second side 220 and the first side 210, and a third column 240 is located on the first side 210.

A cavity 260 is formed between the second column 239 and the first column 238. A filler 262 can be placed in the cavity 260. In the preferred embodiment, the filler 262 is insulation material. In the second column 239 a series of grooves 249 can be cut into a face of the blocks 20 using a router or some similar tool or device. The grooves 249 form a pattern for radiant heating tubes and wiring 250 to be at least partially placed within the grooves 249. After placement of the radiant heating parts, the third column 240 can be placed. Depending if there is space between the second column 239 and third column 240, additional filler 262 could be placed in that space. Such filler could be sand or insulation.

Having thus described the invention in connection with the preferred embodiments thereof, it will be evident to those skilled in the art that various revisions can be made to the preferred embodiments described herein without departing from the spirit and scope of the invention. It is my intention, however, that all such revisions will be included within the scope of the following claims. 

What is claimed is as follows:
 1. A wall system, comprising: a block; the block having a top and a bottom; the block having a first side and a second side; the block having a front side and a back side; the first side has a tongue; the second side has a groove; wherein the tongue of the block is configured to fit in the groove of a second block; the back side has a first channel; a frame; the first channel configured to accept a first portion of the frame.
 2. The wall system of claim 1, wherein: there are a plurality of the blocks; the frame has a first side and a second side; blocks are attached to the first side; blocks are attached to the second side.
 3. The wall system of claim 2, wherein: at least one cavity is formed between the first side and the second side of the frame.
 4. The wall system of claim 3, wherein: a filler is placed in the at least one cavity.
 5. The wall system of claim 4, wherein: the filler is sand.
 6. The wall system of claim 5, wherein: the frame comprises a plurality of vertical support members; each block makes contact with at least three vertical support members.
 7. The wall system of claim 6, wherein: each block comprises a second channel and a third channel; the second channel makes contact with a first vertical support member; the third channel makes contact with a second vertical support member.
 8. The wall system of claim 7, further comprising: a fastener attaching each block to the frame.
 9. The wall system of claim 8, wherein: the blocks are made from compressed earth.
 10. A block for a wall system, wherein the block is attachable to a frame, the block comprising: a top and a bottom; a first side and a second side; a front side and a back side; the first side has a tongue; the second side has a groove; wherein the tongue of the block is configured to fit in the groove of a second block; the back side has a first channel; the first channel configured to accept a first portion of the frame.
 11. The block of claim 10, further comprising: a second channel and a third channel.
 12. The block of claim 11, comprising: the block is made of compressed earth.
 13. The block of claim 12, further comprising: a fastener; the fastener attaches the block to the frame.
 14. A method for building a wall, comprising the steps of: building a frame; attaching a plurality of blocks on a first side of the wall; attaching a plurality of blocks on a second side of the wall wherein the first side is opposite of the second side; wherein each block comprise a first channel on a back side of the block; the first channel accommodates a portion of the frame.
 15. The method of claim 14, wherein: a cavity is between the first side and the second side.
 16. The method of claim 15, further comprising the step of: filling the cavity with sand.
 17. The method of claim 16, wherein: each block has a second channel; the second channel configured to contact a second portion of the frame.
 18. The method of claim 17, wherein: each block has a third channel; the third channel configured to contact a third portion of the frame.
 19. The method of claim 18, wherein: each block is made from compressed earth.
 20. The method of claim 19, further comprising the steps of: cutting grooves in a plurality of blocks; placing heating elements within the grooves; placing an additional column of blocks on the first side. 